Electrochemical cell electrode containing an expanded metal grid



Apnl 27, 1965 HORN ETAL ELECTROCHEMICAL CELL ELECTRODE CONTAINING AN EXPANDED METAL GRID 4 Sheets-Sheet 1 Original Filed Jan. 21, 1960 mmwmw A GENT 3,180,761 ING April 27, 1965 L HORN ETAL ELECTROCHEMICAL April 27, 1965 HORN ETAL ELECTROCHEMICAL LUTZ OR and Y FRITZ PHIL/PP MMWLWMQ/ AGENT United States Patent 4 Claims. (Cl. 136-51) This is a division of application Serial No. 3,914, filed January 21, 1960, now Patent No. 3,099,899, granted August 6, 1963.

The present invention relates to improvements in electrodes for electrochemical cells, and more particularly to improve grids for battery plates.

Expanded metal has proved to be of value as a grid for pasted storage battery plates, the active electrode material being completely or partly carried in the mesh openings of an expanded metal sheet constituting the grid of the electrode. More recently, attempts have been made to use electrode grids consisting of two kinds of expanded metal of different mesh size in the form of a laminated structure. 7

Conventional expanded metal sheets are made by cutting slits into a metal sheet or foil and then stretching the same. In this process, the bonds of the expanded metal sheet form slanted planes in respect of a plane extending centrally within the sheet. The thickness of the expanded metal structure is determined by the width of these, planes in the direction in which the slitted metal sheets are stretched and by their angle of inclination. The connecting strands between the bonds are about half the width of the bonds but have the same angle of inclination. When looking at the expanded metal structure in the direction of the planes of the bonds, the entire structure gives the appearance of honeycombed, approximately hexagonal webs.

When operating a storage battery, the direction of the current lines is usually vertical to the plane of the electrode. Using conventional expanded metal grids for such electrodes, the available area traversed by the current and the effective surface of the active mass will be decreased more or less, depending upon the angle of inclination of the strands and bonds in relation to the central plane of the plate. The thickness of the stretched grid and the angle of inclination are correlated to each other. An almost vertical arrangement of the strands in the stretched grid is possible only if the strands are nickel carbonyl powder sintered to the grid. Such electrodes tend to lose their active material during operation of the battery. The service life of storage batteries in which the carrier of the active mass is a conventional expanded metal grid is thus considerably decreased and the voltage level and the efficiency of the active mass are noticeably impaired.

It is, therefore, one object of the present invention to provide a novel expanded metal structure as the grid carrying the active material of an electrochemical cell elec- Patented Apr. 27, 1965 trode, which grid is substantially free of the disadvantages of conventional expanded metal grids, which facilitates access of the electrolyte to the active mass, which considerably'increases the elfective surface and, thus, the chiciency of the active material, and which, at the same time, increases the adherence of the active material to the grid and substantially diminishes shedding and spilling of the active material.

Other objects and advantageous features of the present invention will become apparent as the description of a preferred embodiment thereof proceeds.

The expanded metal sheet constituting the electrode grid of this invention is produced by first stamping or cutting small slits into a suitable metal sheet or foil and stretching the slitted sheet or foil into an expanded metal structure having mesh openings. Thereafter, the resulting expanded metal structures bonds and strands are slitted and stretched, the latter slits beinglarger than the slits cut for the preliminary stretching step. The second stretching step results in an expanded metal sheet with small and large mesh openings. This double-stretched, three-dimensional expanded metal sheet consists of metal strips having bonds and strands, the strands interconnecting the bonds and each four adjacent ones of the bonds interconnected by four of the strands defining a mesh opening. The metal strips are slanted transversely in respect of a plane extending centrally within the sheet. Each of these strips also is a three-dimensional expanded metal sheet and each strip also has bonds and strands defining additional mesh openings therebetween. The latter bonds and strands are slanted transversely in respect of a plane extending centrally therewithin and the adidtional mesh openings are substantially smaller than the firstmentioned mesh openings. Electrode grids made of such expanded metal grids with mesh openings of different sizes permit better pasting of the active material carried within the mesh openings or better introduction of active material metal powder to be sintered to its bonds and strands. The active mass or sintered metal powder adheres considerably better thereto. The active mass or sintered metal powder is distribtued throughout the smaller and larger mesh openings in such grids. The recesses, notches, and the like produced in the second stretching step in the strands and bonds defining the larger meshes considerably improve the adherence of the active material or sintered metal to the-expanded metal grid. As a result thereof, the active material or sintered metal are firmly bonded to, and united with the grid. At the same time, the grid serves as the current conductor for the plate.

Due to the fact that. the expanded metal grid is obtained by stretching the sheet twice, the total volume of mesh openings and, consequently, its receptivity for the active massis increased.

The expanded metal sheet grids of the present invention may be made of any suitable electrolyteresistant metal, for instance, nickel and nickel alloys. Alternatively or additionally, the grid may be provided with a protective surface layer, for instance, by-lanodie oxidation, in which case the sheet metal itself need not be resistant to electrolyte corrosion. If desired, two or more layers of the expanded metal may belaminated to yield especially effective electrode structures. Alternatively, such laminated grids may be formed of novel expanded metal sheets combined with conventional expanded metal sheets and/ormetal wire nets and the like.

For a further understanding of the present invention reference is to be had to the following description and the accompanying drawings, wherein:

FIG. 1 illustrates a top view of a metal sheet provided with small cuts for preliminary stretching;

FIG. 2 illustrates a top view of an exeanded metm sheet after preliminary stretching according to the present invention; 7

FIG. 3 illustrates a top view of a prestretchcd expanded FIG. 6 illustrates a sectional View through a composite electrode grid composed of two expanded metal grid according to the present invention and; a non-expanded compact metal sheet therebetween.

In these figures, like reference numerals indicate like parts tln'oughout the several views.

FIG. l'shows the small incisions ll cut into the unexpanded metal sheet. FIGS; 2 and 3 show bonds 2 of the expanded metal sheet between mesh openings 4 and strands 3 connect ing the bonds 2 and forming therewith the mesh onenings 4. In FIG. 3 larger slits 8 are stamped or cut into the preliminary expanded metal sheet of 516.2. In

FIG. 4 there are illustrated smaller mesh openings 4 formed by bonds 2 and strands 3, while larger mesh openings are formed by strands '7 and bonds 6. The latter strands and bonds do not-consist of compact metal but, as can readily be seen, are formed of the expanded metal obtained on prestretching. In this manner, the double stretched expanded metal sheet 9 according to the present invention is obtained.

FIG. 5 illustrates electrode 10 composed of the double stretched expanded metal grid 11 with lug l2. Said grid 11 contains active mass 13 pasted in the small mes openings 4 as well as in the large-rmesh openings 5. Said grid 11 is mounted in fname 14.

FIG. 6 is a cross-sectional view through a three-ply metal sheet consisting of the double stretched expanded metal sheets 9 and a solid unexpanded metal sheet 15, the three sheets being kept in close contact with each other by frame 16. The solid metal sheet 15 may be replaced by a conventional expandedmetazl sheet. It imparts greater stability and rigidity to the expanded metal "sheets.

The metal sheets to be expanded may have any desired thickness. For electrodes made of steel, 2. thickness between about 0.8 mm. and about 1.5 mm. has

proved to be satisfactory.

The slits or incisions cut into the metal sheet for producing the pro-stretched expanded metal sheet of FIG. 2 are, of course, smaller than the slits or incisions 8 (FIG; 3) cut or stamped into the pro-stretched expanded metal sheet (FIG. 2). The difference in length of the 'unexpanded incisions l, on the one hand, and the unexpanded incisions 8, on the other hand, is between about 1:2 and about 1:10; The preferred difference in length is about 1:5 although the invention is not limited thereto.

The small slits or incisions in the pro-stretched expanded metalsheet (FIG. 2) have, for instance, a length etwecn about 0.6 mm. and about 1.2 mm. and prederably a length between about 0.8 mm; and 1.0 mm.

The distance between the incisions in horizontal direction :is between about 0.3 mm. andabout 1.2 and preferably between about 0.4 and about 0.5 mm., while the distance in vertical direction, is. vertically to the incisions is between about 0.1 mm. and about 0.4

mm. and preferablybetween about 0.15 mm. and about i.e. vertically to the larger incisions is between about 0.6 mm. and about 2.0 mm. and'preferably between about 0.8 mm. and about 1.2 mm. 1

Preliminary stretching to produce the expanded metal 1 sneet structure of FlGIZ is effected by placing the one distance between the incisions in horizontal direction and 0.2 mm, distance in vertical direction a force of 10.0

kg./sq..cm. is applied while for sheets of lead alloy as they are used for electrodes in storage batteries and having the same thickness and arrangement of incisions, the force to be applied is 10.0 kg./sq. cm As the art of producing exmetal is Well. known and familiar to those skilled in this field, it is understood that'only so'much of this procedure will be described aswill be necessary for an understanding of this invention. Many details of the stretching process and apparatus are omitted as interfering with a consideration'of the invention and will readil be supplied by those skill d in thisart.

Likewise, when carrying out final stretching of the p e-expanded metal sheet of HG. 3,'the stretching force to be applied to one end of the metal sheet depends upon the material composing, an the thickness of, the metal sheet and the size of the incision; Forinstancefor pre stretched expanded nickel sheets, as described hereinabove, with large incisions of 6.0 mm. length and a distance of 3.0 mm. between the .incisionsin horizontal direction and ot 1.5 mm. in vertical direction, a force of 10.0 kg/sq. cm. is applied while vfor sheetsof lead alloy as. described above for "pm-stretched expanded nickel sheets, the. stretching forceto be applied is about 10.0 kg./sq.cm. l

It is. understood that the larger cuts or incisions can be provided not only parallelto the smaller incisions but also veritcal or at an angle thereto. 7

As pointed out hereinabove, the double stretched ex-.

panded metal sheets according to the present invention are of particular usefulness for making. electrodes for storage batteries. The available area traversed by the current and the effective surface of the-active mass are considerably increased in comparison to thatof conventional expanded metal electrodes so that the active mass is more fully utilized .thanheretofore possible, andthe service life of the electrodes is prolonged due'to the better adherenceof the active mass to the grid. 0 Of course many changes and variations in the composition of the metal sheets used for making the double stretched expanded metal according to the present invention,'in the size and arrangement of the slits or incisions, in the forces used-for pre-stretching and for final stretching, and the like may be made bythose skilled in the art in accordance with the principles set forth herein'and in the claims annexed hereto.

We claim; g

1. in an electrochemical cell: an electrode comprising a three-dimensional xpanded metal grid, said grid being a metal sheet consisting of metal strips having bonds and strands, the strands interconnecting the bonds and.each four adjacent ones of the bonds interconnected by four of the strands defining a mesh opening, the metal strips being slanted transversely in respect of a plane extending centrally Within the sheet, each, ofsthe -etal strips being a three-dirnensional expandedmetalsheet, each 1of the strips also having bonds and strands defining additional mesh openings therebetween, thelatterbonds and strands being slanted transversely in respect of a plane-extending centrally therewithin, the additional mesh openings being substantially smaller than the first-mentioned mesh openngs, active materialwithin the mesh openings of the 7 grid, and an outer framework holding the grid, the outer 5 framework being more rigid than the expanded metal grid.

2. The electrochemical cell electrode of claim 1,

wherein the first-mentioned mesh openings of the grid 905952 have a length about two to ten times that of the addi- 2909586 tional mesh openings. 3O69486 3. The electrochemical cell electrode of claim 2,

wherein the length of the first-mentioned mesh openings 607 815 is about five times that of the additional mesh openings.

4. The electrochemical cell electrode of claim 1, wherein the first-mentioned bonds have about twice the width of the first-mentioned strands.

6 Reterences Cited by the Examiner UNITED STATES PATENTS 12/08 Szek 136120 10/59 Hagspihl 136-28 12/62 Solomon et al 136-30 FOREEGN PATENTS 11/ 60 Canada.

10 JOHN H. MACK, Primary Examiner. 

1. IN AN ELECTROCHEMICAL CELL: AN ELECTRODE COMPRISING A THREE-DIMENSIONAL EXPANDED METAL GRID, SAID GRID BEING A METAL SHEET CONSISTING OF METAL STRIPS HAVING BONDS AND STRNDS, THE STRANDS INTERCONNECTING THE BONDS AND EACH FOUR ADJACENT ONES OF THE BONDS INTERCONNECTED BY FOUR OF THE STRANDS DEFINING A MESH OPENING, THE METAL STRIPS BEING SLANTED TRANSVERSELYIN RESPECT OF A PLANE EXTENDING CENTRALLY WITHIN THE SHEET EACH OF THE METAL STRIPS BEING A THREE-DIMENSIONAL EXPANDED METAL SHEET, EACH OF THE STRIPS ALSO HAVING BONDS AND STRANDS DEFINING ADDITIONAL MESH OPENINGS THEREBETWEEN, THE LATTER BONDS AND STRANDS BEING SLANTED TRANSVERSELY IN RESPECT OF A PLANE EXTENDING CENTRALLY THEREWITHIN, THE ADDITIONAL MESH OPENINGS BEING SUBSTANTIALLY SMALLER THAN THE FIRST-MENTIONED MESH OPENINGS, ACTIVE MATERIAL WITHIN THE MESH OPENINGS OF THE GRID, AND AN OUTER FRAMEWORK HOLDING THE GRID, THE OUTER FRAMEWORK BEING MORE RIGID THAN THE EXPANDED METAL GRID. 